Spray cooling system for transverse thin-film evaporative spray cooling

ABSTRACT

A spray cooling system for transverse thin-film evaporative spray cooling in a narrow gap which generally includes a framework, a cooling cavity, a plurality of atomizers oriented to transversely spray coolant across the electronic components to be cooled, and preferably a vapor recirculation system and a reduction in cross section from the inlet or spray side to the exit side.

TECHNICAL FIELD

This invention relates to an evaporative spray cooling system fortransverse evaporative thin-film spray cooling of electronic components,in either a single circuit card or stacked circuit card, narrow-gapconfiguration.

BACKGROUND OF THE INVENTION

As electronic components continue to advance and are made more powerful,they tend to produce more and more undesirable heat which is preferablyremoved. This has created a growing need for higher capacity coolingsystems to remove heat from all or a portion of the electroniccomponents.

As the trend is to make electronic components more powerful, there isalso an increasing push to reduce the size of the electronic components,and the packaging of the electronic components. The smaller componentsand packaging makes the removal of the unwanted heat more difficult.

In some applications, direct impingement thin-film evaporative spraycooling is preferred in order to provide sufficient cooling, whereas inother application spray cooling is desired to reduce the overall packageor housing size even though the required cooling capability is not ashigh. This creates a situation in which transverse narrow gapevaporative spray cooling is advantageous if it can be done to anacceptable efficiency level.

Narrow gap evaporative spray cooling will preferably provide or spraythe spray coolant from a transverse side of the electronic components orcircuit card, through an atomizer, and thereby transversely spray thecoolant or cooling fluid.

Proper cooling is preferably achieved if a thin liquid film ismaintained over the device or electronic component to be cooled, therebyfacilitating evaporation of the coolant as heat is transferred from theelectronic component. If there is too little flow or coverage ofcoolant, the liquid layer covering the electronic component will dry outand cause the component to overheat because convection will nottypically provide sufficient heat transfer. If the flow of coolant tothe component is too great, the device will become flooded and mayproduce hot spots, insufficient cooling and/or failure, because thevapor created from the evaporation may become trapped between theexcessive fluid and the impingement surface of the electronic component.This will normally reduce the cooling efficiency. Vapor generated at thesurface of the component cannot escape effectively and could result in aboiling heat transfer failure mode generally referred to as burnout.

Even when the volume flux of coolant is properly matched to the heatflux of the device, the excess fluid sprayed within a cavity must bemanaged by the method described in U.S. Pat. No. 5,220,804 to preventthe overflow from adjacent components from interfering and causingflooding type failure conditions.

It is therefore an objective of this invention to provide a narrow gap,thin-film, evaporative spray cooling system for cooling one or moreelectronic components in the narrow gap.

BRIEF DESCRIPTION OF THE DRAWINGS

Preferred embodiments of the invention are described below withreference to the following accompanying drawings.

FIG. 1 is a perspective schematic of a prior art configuration andtraditional way of providing cooling for various components of a system;

FIG. 2 is a perspective schematic representation of a much more compactversion of a system with the same capabilities as that in FIG. 1, onlywhich utilizes features or embodiments of the invention;

FIG. 3 is a perspective view of one embodiment of a spray cooling systemfor transverse thin-film evaporative spray cooling with a plurality ofcircuit cards with electronic components thereon;

FIG. 4 is a perspective breakaway view of an embodiment of a single cardtransverse thin-film evaporative spray cooling system with a card edgeelectronic connector;

FIG. 5 is a perspective view of another electronic system which utilizesan embodiment of this invention and may be a component within athree-dimensional electronic cooling configuration;

FIG. 6 is an end view of stacked circuit cards, each with electroniccomponents and configured for transverse evaporative spray cooling;

FIG. 7 is a top view schematic representation of an embodiment of aspray cooling system contemplated by this invention, showing a vaporrecirculation system;

FIG. 8 is a top schematic representation of another embodiment of thisinvention which includes a different embodiment of a vapor recirculationsystem and a vapor utilization system;

FIG. 9 is an elevation view schematic of an embodiment, of thisinvention where the cooling cavity is tapered to provide beneficialcooling effects;

FIG. 10 is an elevation schematic view of an embodiment of thisinvention wherein the first electronic component to be cooled is angledrelative to the circuit card on which it is mounted to provide animpingement angle for predetermined cooling properties and a secondelectronic component at a greater impingement angle;

FIG. 11 is an elevation schematic representation of an embodiment ofthis invention in which successive electronic components are mounted toa circuit card in a stepped configuration;

FIG. 12 is a schematic depiction of a first dimension of a spray patternor cone which may be generated in an embodiment of this invention by anatomizer for a narrow gap application;

FIG. 13 is a side view of the spray pattern illustrated in FIG. 12 andshows a second and different dimension of the spray pattern;

FIG. 14 is a schematic representation of an approximate spray patterngenerated by the spray pattern configuration dimensions shown in FIGS.12 and 13;

FIG. 15 is another schematic representation of another of the numerouspossible two-dimensional spray pattern configurations that may beutilized as part of this invention;

FIG. 16 is a schematic representation of a spray pattern created byrelative sizing of layers at the atomization nozzle, showing anapproximate angle of 30 to 45 degrees;

FIG. 17 is a schematic representation of a spray pattern created byrelative sizing of layers at the atomization nozzle, showing anapproximate angle of 45 degrees;

FIG. 18 is a schematic representation of a spray pattern created byrelative sizing of layers at the atomization nozzle, showing anapproximate angle of less than 30 degrees; and

FIG. 19 is an elevation schematic representation of a gap fillerinserted between respective electronic components to obtain a morefavorable heat transfer.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Many of the fastening, connection, manufacturing and other means andcomponents utilized in this invention are widely known and used in thefield of the invention described, and their exact nature or type is notnecessary for an understanding and use of the invention by a personskilled in the art or science; therefore, they will not be discussed insignificant detail. Furthermore, the various components shown ordescribed herein for any specific application of this invention can bevaried or altered as anticipated by this invention and the practice of aspecific application or embodiment of any element may already be widelyknown or used in the art or by persons skilled in the art or science;therefore, each will not be discussed in significant detail.

The terms “a”, “an”, and “the” as used in the claims herein are used inconformance with long-standing claim drafting practice and not in alimiting way. Unless specifically set forth herein, the terms “a”, “an”,and “the” are not limited to one of such elements, but instead mean “atleast one”.

Applicant hereby refers to and incorporates by this reference thefollowing U.S. patents: U.S. Pat. No. 5,675,473 issued Oct. 7, 1997;U.S. Pat. No. 5,220,804 for a high heat flux evaporative spray coolingsystem; and U.S. Pat. No. 5,860,602 and U.S. Pat. No. 6,016,969, eachfor a laminated array of pressure swirl atomizers. The laminated arrayof pressure swirl atomizer patents referred to above may be utilized asone way or mechanism to accomplish the atomizing, even though there arenumerous others which are available and now known in the art, such asbutton atomizers and others.

FIG. 1 is a perspective schematic representation of a prior art system600 showing power supply 601, ribbon connector 602, memory section 605with ribbon connector 604, and processor 603.

FIG. 2 is a preferred size and packaging configuration as provided byembodiments of this invention, and illustrates a reduced size that maybe accomplished by an integrated spray cooling system as contemplated bythis invention. FIG. 2 illustrates the computer system 610, including apower supply 611, a processor 612 and a memory 613, in a cubeconfiguration. For relative sizing comparison purposes, each of thecubes in FIG. 2 may be approximately 4 inches per side, whereas thecomponents in FIG. 1 would be much larger. For instance the memory 605in FIG. 1 would be approximately 8 inches square, the processor 603would be approximately 4 inches square, and the power supply 601 wouldbe approximately 30 inches square.

It will be appreciated by those of ordinary skill in the art thisspacing savings by integrating a spray cooled approach to all threecomponents. The configurations shown in FIGS. 1 and 2 are generallyreferred to as cube computers, and the configuration in FIG. 2 on anintegrated platform may be at five times reduction in sizing with thecurrent cube computer configurations as shown in FIG. 1.

FIG. 3 is a perspective breakaway view of another utilization of anembodiment of this invention wherein transverse evaporative thin-filmspray cooling is utilized in narrow gaps to cool electronic componentson circuit cards which are stacked in close configuration. FIG. 3illustrates the cooling system 620 with housing 621, a first circuitcard 622 with electronic components 623 mounted thereon. Coolantatomizer 624 provides coolant spray transverse to the electroniccomponents to provide a predetermined amount of cooling in the narrowgap cooling cavity or channel. Second circuit card 625 with electroniccomponents 626 is at a level lower than first circuit card 622 andatomization nozzles 627 provide transverse evaporative spray cooling tothe electronic components 626 on the second circuit card 625. The system620 has a plurality of layers of cooled circuit cards and electroniccomponents as represented by item 621. Since the system 620 shown inFIG. 3 is a closed system, reservoir 631 is provided for the coolingfluid and fans 630 provide cooler air for a condenser provided therein.While an air cooled condenser is shown, the invention is not limited tothis type of condenser, but instead other types of refrigeration andother condenser systems may be utilized within the scope of theinvention.

Generally, narrow gap cooling cavities are a reference to the height ofthe channel, in the approximate range of 0.020 to 0.125 inches in height(from the top surface of the circuit card to the ceiling surface of thecavity lid or opposing side). The width of the channel or cooling cavityis generally much greater than the height, but wider channels can simplybe accommodated with more atomizers along the width. The length of thecooling cavity or channel may be as long as fifteen to twenty inches,although it may also be much shorter, in the range of one inch. Innarrow gap spray cooling applications, as discussed more fully below,the use of vapor at the spray side of the cooling cavity is beneficialin the cooling characteristics in the entire channel or cavity, whetherthe vapor has been recirculated or developed through other techniques,as described more fully below.

For purposes of this invention, the transverse spray cooling generallyrequires pumps (preferably positive displacement pumps) to provide theliquid coolant to the atomizers, a return system to direct the fluid toa reservoir, a condenser to condense the vapor and vapor/liquid mixtureto a liquid form.

FIG. 4 is a perspective cutaway view of a single circuit cardapplication or embodiment of this invention, illustrating a closedtransverse evaporative spray cooling system 640 with housing 644, fluidinlet 643, fluid outlet 642, a plurality of electronic components 645mounted on circuit card 647, or printed circuit board, a plurality ofliquid atomizers 646 providing atomized liquid coolant to the electroniccomponents 645 being cooled. The cooling cavity 649 is generallyenclosed by housing 644, and in this case is a narrow gap configurationwith the electronic components 645 having an electrical connector 647configuration as a card edge connector.

It will be appreciated by those of ordinary skill in the art that thenumber of possible applications of this invention are numerous and eachof the individual components may have numerous types or configurationswhich may be utilized all within the contemplation of this invention.For instance, there are numerous types of electrical connectors that canbe made or utilized to provide electrical connections between theelectronic components 645, the circuit card 647, and the card edgeconnector 641.

FIG. 5 is a perspective view of another embodiment of a transverse spraycooled evaporative thin-film cooling system contemplated by thisinvention, illustrating circuit card 651, atomizers 652, fuzz buttonconnector 655 for interconnecting circuit card 651 with others stackedabove or below it, electronic component 654 with heat spreader 653mounted thereon, and to provide improved heat transfer characteristicsbetween the coolant received from atomizers 652 and electroniccomponents 654. The coolant cavity 656 is a predetermined width, height658 (preferably narrow gap) and length from the spray side (near theatomizers) to the exit side.

It will be appreciated by those of ordinary skill in the art that thereare numerous narrow gap configurations in which electronic componentsmounted on circuit boards need to be cooled, and the system 650illustrated in FIG. 5 is merely one of numerous examples thereof, withno particular configuration being required to practice this invention.

FIG. 6 is an end view looking from the exit side to the spray side of athree-dimensional or stacked transverse evaporative spray cooling system670. The stacking creates multiple narrow gaps. FIG. 6 illustrates afirst circuit card 676 with electronic components 677 mounted thereonand a first plurality of atomizers 673 for providing spray coolant tothe first electronic components 677. Second circuit card 678 haselectronic components 679 mounted thereto and a second plurality ofatomizers 683 providing spray coolant through the narrow gap and to theelectronic components 679. The first circuit card 676 is interconnectedwith the second circuit card 678 by known board-to-board interconnects682. Although this type of interconnection is utilized in thisinvention, as will be appreciated by those of ordinary skill in the art,numerous others are available and no one in particular is required topractice this invention.

FIG. 6 further shows third circuit card 680 with electronic components681 mounted thereon and a third plurality of atomizers 685 providingspray cooling through the narrow gap to the electronic components 681.

The evaporative spray cooling atomizers are providing the spray fluidtransversely, i.e. from the side of the electronic components.

FIG. 6 also shows another embodiment or feature of the invention whereinthe plurality of atomizers is vertically staggered with respect to oneanother to provide the predetermined cooling characteristic for theelectronic components being cooled. FIG. 6 illustrates the firstplurality of atomizers has vertically higher atomizers 672 which arestaggered from the other atomizers by vertical offset 671. There may bemany instances in which it is desirable to achieve different flowcharacteristics by elevating some atomizers relative to others within aplurality.

There are also benefits, flow characteristics and coolingcharacteristics which may be achieved by slightly angling the normalangular configuration of the atomizer. Typically in a laminated atomizersituation, the atomizers spray coolant at approximately perpendicular tothe surface from which the atomizers are spraying (approximatelyparallel to the circuit card). However, relative to the spray patternand the circuit card, the atomizers may preferably be angled at anapproximate three (3) to five (5) degree angle (normally measured fromthe center line of the spray pattern) and elevated for improved coolingcharacteristics on the electronic components being cooled within thecooling cavity.

FIG. 7 is a top schematic view of an embodiment of a transverseevaporative spray cooling system for thin-film cooling of electroniccomponents and further illustrates a configuration for one embodiment ofa vapor recirculation system in connection with a narrow gap coolingcavity or channel. FIG. 7 illustrates a transverse evaporative spraycooling system 700 with an internal cooling cavity 703, a plurality ofspray cooling atomizers 701, a plurality of electronic components 705mounted on circuit card 704, or printed circuit board, an exit 702 and afirst vapor recirculation conduit 706 in which vapor 711 is recirculatedto vapor re-entry port 709. FIG. 7 further illustrates a secondrecirculation conduit 707 with vapor 710 routed there-through forintroduction back into the cooling cavity through vapor port 708.

It should also be noted that it is generally preferably to have a reliefarea, slot, etc. where the coolant may be received near the exit side ofthe cooling cavity to that the fluid does not collect and tend tobackup, thereby causing pooling or impeding the thin film evaporativecooling occurring. This allows the combination of the coolant and thevapor to maintain thin film flow and evaporation. The relief area neednot be in any one location and may vary with the orientation of thespraying, such as upward, downward, horizontally, or any combinationthereof.

FIG. 8 is a top schematic representation of another embodiment of thetransverse evaporative spray cooling system 730 contemplated by thisinvention. FIG. 8 illustrates a cooling cavity 729 with a spray side 733and an exit side 734, the exit side being nearer the exit 735 than thespray side. A plurality of atomizers 741 provides coolant to the coolingcavity 729 to cool electronic components 732 mounted on circuit card731. The system 730 illustrated in FIG. 8 further shows a first vaporrecirculation conduit 737 routing vapor 738 through the conduit andreintroducing it at or near the spray side 733 of the cooling cavity729. Similarly, vapor recirculation conduit 739 routes vapor 740 forreintroduction into the cooling cavity nearer the spray side 733 of thecooling cavity 729.

It should be noted that the electronic components 732 have beenstaggered relative to one another in the stream of movement of coolingfluid and vapor. The electronic components 732 have been positioned inpredetermined locations to avoid any blockage or impingement of spraycooling from a first electronic component nearer the spray side 733 ofthe cooling cavity 729 for a downstream electronic component near theexit side.

FIG. 8 also illustrates another embodiment of this invention wherein thecooling cavity 729 is tapered from the spray side 733 to the exit side734 via sidewall 736 configuration. In many applications, embodiments ofthis invention which provide decreasing cross-sectional area from thespray side 733 to the exit side 734 create beneficial flowcharacteristics and acceleration of vapor in the system, to providebetter or more desirable cooling, especially for electronic componentsnearer the exit side 734 of the cooling cavity 729. The tapering neednot be any particular percentage reduction, but a tapering toapproximately one-half of the cross-sectional area from the spray sideof the cavity to the exit side is one that is used and seems to work.

FIG. 8 further shows a heat exchanger system 742 which pre-heats thecooling fluid or coolant before it is provided to the atomizers. Theheat exchanger or pre-heater is sometimes referred to as a cold plate.When the coolant is pre-heated to above its normal boiling temperature(it is generally under pressure) and is then atomized through theatomizer nozzles, the additional energy or heat in the fluid from beingabove its normal boiling temperature is released and the fluid ispartially vaporized until the coolant gets down to its approximatenormal atmospheric boiling temperature. Providing vapor throughpre-heating provides additional flow control and helps reduce or preventthe eddies from detracting from the flow and the heat transfer.

FIG. 9 is an elevation schematic representation of another embodiment ofthis invention in which the cooling cavity 749 has a decreasingcross-sectional area from the spray side to the exit side thereof. Thecooling cavity lid 755 is angled downwardly toward the exit side of thecooling cavity, with the distance from the circuit card 751 to thecavity lid 755 at the spray side is distance 754, whereas the distancebetween the circuit card 751 and the lid 755 at the exit side isdistance 756, wherein spray side distance 754 is greater than exit sidedistance 756. Electronic components 752 are mounted on the circuit card751 in the system 750 illustrated in FIG. 9.

FIG. 10 is an elevation schematic representation of another embodimentof the invention which is utilized to obtain predetermined coolingcharacteristics and illustrates an impingement surface angling system760 wherein the electronic components are mounted at an impingementangle relative to the circuit card to obtain different flowcharacteristics. FIG. 10 further illustrates in schematic fashion anelectronic component nearer the exit side of the cooling cavity being ata greater impingement angle than an electronic component upstream nearerthe spray side of the cooling cavity, for predetermined desired relativecooling effects.

FIG. 10 illustrates a cooling system 760 which utilizes the respectiveangles of the impingement surfaces of the respective electroniccomponents 763 and 764, with flow arrow 762 indicating the direction offlow of the atomized spray cooling fluid for cooling. FIG. 10illustrates circuit card 761 with first electronic component 763 mountedat impingement angle 759 relative to circuit card 761. The impingementsurface 765 of first electronic component 763 is shown, and theimpingement angle is achieved by mounting the spray side of electroniccomponent 763 of a height less than the exit side of first electroniccomponent 763. Impingement angle 759 is shown for first electroniccomponent 763. While this invention contemplates the angling of oneelectronic component, it also contemplates one or more electroniccomponents being angled and additional desirable characteristics whichmay be achieved by providing a greater impingement angle for downstreamelectronic components being cooled. FIG. 10 shows second electroniccomponent 764 with impingement surface 766 mounted at impingement angle767 relative to circuit card 761.

It has been discovered that greater heat transfer or coolingcharacteristics may be achieved by varying the angle of impingement orthe angle at which a surface to be cooled is impacted by spray droplets.There can be an appreciable difference between cooling characteristicsof electronic components when the spray droplets impact perpendicular tothe surface versus hitting it at an angle less than ninety degrees. Theembodiment illustrated in FIG. 10 utilizes those characteristics toprovide an optimized cooling system and cooling for the electroniccomponents mounted toward the exit side of the cooling cavity.

FIG. 11 is an elevation schematic representation of another embodimentof this invention in which the mounting of the electronic components isaltered from normal practice to achieve more desirable coolingcharacteristics. FIG. 11 illustrates a transverse evaporative spraycooling system 780 in which the respective electronic components aremounted in a stepped or varying height manner from the spray side of thecooling cavity to the exit side. The spray side of the cooling cavity inthe schematic representation would be near the flow arrow 787 (whichindicates the direction which the spray coolant is traveling).

FIG. 11 illustrates circuit card 781 with first electronic component 783mounted thereon via pins 787 and with impingement surface 784. Theheight of impingement surface 784 relative to the top surface of circuitcard 781 is distance 790. Second electronic component 786 withimpingement surface 788 is mounted by pins 789 at impingement surfaceheight 791. Please note that distance 791 from the top surface ofcircuit card 781 to the impingement surface 788 is greater than distance790 for the first electronic component 783. The first electroniccomponent 783 is nearer the spray side of circuit card 781 than secondcomponent 786.

Further shown in FIG. 11 is third electronic component 792 withimpingement surface 795, third electronic component 792 being mounted bypins 793 at height 794 from the top surface of circuit card 781. It willbe observed that third electronic component 792 has an impingementsurface 795, at a greater height relative to circuit card 781 than boththe second electronic component 786 and the first electronic component783.

The stepping or staggering of the heights of the impingement surfaces ofthe respective electronic components may be utilized, to achieveimproved cooling characteristics, especially of downstream electroniccomponents nearer the exit side.

FIG. 12 illustrates a front elevation view of one of numerous potentialspray patterns or cones 800 which may be utilized as part of thisinvention, illustrating first dimension 803, second dimension 801 andcone angle 802. Because the spray is projected into a narrow gap cavity,it is preferred that the spray pattern not be a circular cone butinstead it be more elliptical or it be configured such that a firstdimension corresponding to the width of the narrow gap or cooling cavitybe much greater than a second dimension corresponding to the height ofthe narrow gap cooling cavity. If a circular cone shape spray pattern isutilized in narrow gap evaporative spray cooling, it will likely resultin a larger than desired amount of coolant spray reaching the electroniccomponents near the inlet or atomizers, and a less than desired amountof coolant reaching the exit side components, which would result in therequired coolant flow to cool all of the electronic components beingunnecessarily high. Further, an undesirable amount of coolant wouldstrike the lid and be wasted.

FIG. 13 is a side elevation view of the spray pattern 800 shown in FIG.12, illustrating second inlet dimension 804, third cone dimension 805and second dimension cone angle 806. While the dimension at any givenlocation on the spray pattern will vary with the distance from thenozzle outlet, the dimensional angle will dictate the spray pattern in agiven situation. In the embodiment of the invention illustrated in FIGS.12-14, the second dimension angle 806 is less than the first dimensionangle 802 and provides an approximate elliptical pattern which may beadapted or optimized to a particular narrow gap cooling cavityconfiguration.

FIG. 14 is a top view of the spray pattern illustrated in FIGS. 12 and13, showing second inlet dimension 804, first inlet dimension 803, firstspray pattern dimension 801 and second spray pattern dimension 805. Thespray pattern 800 illustrated in FIG. 14 is merely an example, and thereare numerous different shapes and relative sizing of first and seconddimensions that may be utilized in connection with this invention, asillustrated below in reference to FIG. 15.

FIG. 15 is a top view of another spray pattern which may be utilized ina thinner gap configuration than that shown in FIGS. 12-14 andillustrates an elliptical pattern with a first cone dimension 832 and asecond cone dimension 831 for spray pattern 830.

While there may be numerous mechanical and other geometricalconfiguration ways to accomplish various spray patterns and dimensionangles for spray patterns, FIG. 16 illustrates first plate 810 with anozzle aperture distance 820, second plate 811 with nozzle aperturedistance 821 and spray pattern 812 generated by coolant 799 flowingthrough the respective apertures.

It will be appreciated by those in the art that laminated plates orlayers relatively configured will cause different spray patterns andspray pattern dimension angles to achieve the desired results. In FIG.16, the apertures in the dimensions shown in plate 810 and plate 811creating approximately thirty (30) to forty-five (45) degree spraypattern angle in the dimension or direction shown.

FIG. 17 shows an alternative embodiment configuration of spray plateswherein the first spray plate 813 has first aperture dimension 822 lessthan the aperture dimension 823 and second spray plate 814. The aperturedistance 823 is greater than the aperture distance 822 and therebycreates a larger spray pattern 815 dimension angle, as shown in thefigure at approximately forty-five (45) degrees or more. This may be therespective dimensions corresponding to the width of the cooling cavityas opposed to the height.

FIG. 18 is another alternative embodiment configuration of nozzleapertures, showing first spray plate 816 with an aperture distance 824larger than the aperture distance 825 in second spray plate 817, therebycreating a smaller spray pattern dimension angle of the spray pattern818, the angle being shown at approximately thirty (30) degrees or less.This configuration in this dimension may be more appropriately usedcorresponding to the height of the narrow gap cooling cavity.

In another embodiment of the invention and in order to improve flowcharacteristics, flow predictability, and cooling performance in a thinfilm evaporative spray cooling environment, backfill material or gaplevelers may be placed on the circuit board between electroniccomponents, or relative to the impingement surfaces of the electroniccomponents. FIG. 19 is an elevation schematic representation of such anembodiment, illustrating circuit card 850, first electronic component851, second electronic component 852, and gap filler 853. The gap filler853 can be any one of a number of different types of materials, such aspotting material, pre-fabricated material or templates for insertionbetween electronic components, or others, all within the contemplationof this invention.

In embodiments of this invention, it is desired at times to obtain amore uniform coverage of coolant on the electronic components. Duringthe normal course of cooling, without other design features included,most or all of the vapor generated during the cooling process from theevaporation, and all of the unused liquid, generally exit the system. Inmany cases and configurations however, the spraying of coolant from theatomizers is an effective vapor pump and creates a low pressure zone inor near the inlet area, as compared to the pressure zone at the outletarea. This may be referred to as an adverse pressure gradient.

Since fluid, including vapor, tends to flow from high pressure to lowpressure and high pressure tends to develop toward the exit area,conflict develops and eddies tend to develop in the corners near theinlet or spray, atomizers as the vapor tends to move back toward the lowpressure area or zones at or near the atomizers or spray coolant inlet,which is the spray side or the entrance side of the circuit card orcavity in which the electronic components are housed or contained.Interfacial drag of vapor and/or liquid and thin liquid creates a dragor pull on the liquid which is on the impingement surface or surface ofthe electronic components. When the eddies described above occur andsometimes increase in strength, they have the potential to completelyblock off or alter the spray pattern originally obtained and desired.This causes alterations to the heat transfer, thin-film evaporation andthe cooling capacity of the spray cooling system. This condition resultsin more spray coolant being provided to the electronic components nearerthe spray side and less or inadequate coolant being supplied to theelectronic components nearer the exit side, and some electroniccomponents not getting any or sufficient coolant.

In order to reduce or eliminate this problem, this invention utilizes a“vapor recirculation” system. Vapor recirculation within thecontemplation of this invention may be utilized in any one of a numberof different ways. One way is to provide an opening or openings near theexit side of the circuit card or cooling cavity, the apertures oropenings being configured to allow vapor to flow there-through whilealso preferably impeding the flow of liquid.

One of several ways to help keep the liquid out or reduce the liquidwhich enters the exit vapor openings, is to provide the openings with alarge enough cross-sectional area that the entering vapor has a lowvelocity and does not entrain liquid or draw the liquid into theopenings. It is also preferable, although not necessary to practice thisinvention, that the openings are at least initially near perpendicularor more to the direction of travel of the liquid or even in the oppositedirection of the liquid, as liquid does not tend to turn as easily asvapor when flowing. While it would be very difficult to prevent nominalamounts of spray coolant liquid to become entrained, additionalprecautions may be taken to avoid re-introducing non-atomized liquid.

As shown in FIGS. 7 and 8, the vapor is routed back toward the spray orinlet side where it is introduced through one or more apertures oropenings, and thereby provides a vapor velocity to partially or whollyprevent the eddying or backflow effect. If the vapor recirculationconduits are large enough in cross-section, the vapor velocity isreduced and it tends not to draw or entrain as much liquid back towardthe inlet area where the vapor is being redirected. In this case noshroud, is used to control the fluid but instead the vapor in the systemis partially gathered and routed back to or toward the entrance side orthe spray side of the cooling cavity or circuit card.

An alternative vapor recirculation system may involve sizing the coolingcavity sufficiently wide that the vapor can be recirculated at the farsides of such a wider cavity at a low enough velocity within the sidechannels so that liquid would not be entrained and eddies would notdevelop. This is not preferable in applications in which sizeconstraints are more important, and this type of vapor recirculationsystem may tend to lower heat transfer coefficients. In a narrowerchannel application of the vapor recirculation system, the higher vaporvelocities assist in spreading the cooling liquid or coolant and inthinning or reducing the depth of the liquid film over the electroniccomponents, especially toward the exit side of the cooling cavity orchamber.

It will be appreciated by those of ordinary skill in the art that thespecific velocities and thickness of coolant or liquid being evaporatedvaries from application to application and no one in particular isrequired to practice this invention.

Another one of the potential vapor recirculation systems which may beutilized within the contemplation of this invention is to materiallyincrease the amount of coolant that is sprayed and to widen the array ofatomizers which provide the atomized coolant to the cooling cavity. Thiswould have the effect of impinging heavily on the entire circuit cardand electronic components mounted thereon, on all of the channelsurfaces and, in effect, overpowering the vapor trying to backflow oreddy. This embodiment is not preferred in many applications because itrequires a substantially higher flow rate of coolant. Further if oneatomizer becomes weak or inoperative, it will cause a failure of asystem because a lower pressure region would then be created where theatomizer failure occurred.

The typical and preferred coolant utilized with spray in this inventionis fluorinert™, available from 3M. However, this invention is in no waylimited to any one particular coolant, as there are many others whichmay be suitable dielectric coolants, such coolants known and availablein the industry.

Although the invention is certainly not limited to any particular rangefor cooling, under current practice in cooling, the following method isutilized to design an apparatus according to the present invention.First, the individual circuit cards are analyzed according to theindividual device size, power distribution and layout to determine themost desirable spray configuration. Based upon the maximum device heatflux of the individual components, geometry constraints, and the totalboard power level and size, the narrow or transverse spray, angledimpingement, or normal impingement spray configuration is chosen. Thefollowing table serves as a general guideline for spray cooling withperfluorcarbons.

Configuration Max. Device Flux Avg. Board Flux z-axis space Narrow Gap20 W/cm² 20 W/cm² 0.02″-0.25″ Angled Impingement 40 W/cm² 30 W/cm²0.25″-0.375″ Normal Impingement 150 W/cm²  50 W/cm² 0.25″-0.75″ EnhancedSurface 1.5-10.0 × Normal 1.5-10.0 × Normal 0.25″-1.0″

There are other possible embodiments to this invention which may havebenefits such as cost reduction, elimination of diamond processing, andimprovement of the performance, potential, although none of these arerequired to practice the core invention disclosed herein. Recent coolingstudies concerning spray cooling in narrow gaps suggests that a higherperformance approach is possible by actually spraying through thecomputer, rather than relying on costly thick diamond to conduct theheat to the edge. Experiments demonstrate the ability to remove fivehundred (500) Watts per board while accommodating the required boardpitch.

FIG. 5 shows an embodiment of the invention with this modified MCMConcept. The thick diamond substrates and fuzz button retainer boardsare replaced with standard PCB's or ceramic substrates. Thin, roughdiamond squares 653 (heat spreaders) slightly bigger than the chips 654(electronic components) are metallized and attached to the chip backs.The chips 654 are flip tab or flip chip bonded to the standardsubstrates. The boards are then integrated 3-D using progressive wavetube interconnects or other suitable approaches, thus leaving narrowgaps between boards. A spray plate on one side with flat spray atomizerswill direct a droplet mist through the computer and remove the heat fromthe diamond squares through thin film evaporation. The excess liquid andvapor will be collected on the opposite side of the cube.

Embodiments of the invention may also be integrated with a high densityswitch mode power supply. The memory module could also be more closelyintegrated using 3-D memory cubes, such as shown in FIG. 2. Thecomputer, power supply and memory module would all be cooled with “SprayThrough Cooling.” This integrated approach will reduce the number ofinterconnections, reduce the signal path to increase clock speed,improve power insertion, and simplify construction to reduce size andcost.

As will be appreciated by those of reasonable skill in the art, thereare numerous embodiments to this invention, and variations of elementsand components which may be used, all within the scope of thisinvention.

One embodiment of this invention, for example, is for example a narrowgap thin-film evaporative spray cooling system for cooling at least oneelectronic component utilizing a transversely sprayed cooling fluid,comprising: a transverse spray framework defining an at least partialperimeter around a narrow gap cavity, the narrow gap cavity including aheight, a width greater than the height, and a length, disposed to houseat least one electronic component to be spray cooled; a plurality oftransverse atomizers integral with the transverse spray framework at afirst side of the transverse spray framework, the plurality oftransverse atomizers being disposed to receive cooling fluid and tospray the cooling fluid into the narrow gap cavity transverse to the atleast one electronic component; and a cooling fluid outlet in fluidcommunication with the cooling fluid cavity, disposed to receive coolingfluid from the narrow gap cavity and route it to a transverse sprayframework outlet.

Additional embodiments to the foregoing, may be: further wherein theplurality of atomizers are configured to spray the cooling fluid intothe narrow gap cavity in a spray pattern which includes a first spraypattern angle corresponding to the width of the narrow gap cavity and asecond spray pattern angle corresponding to the height of the narrow gapcavity, and further wherein the first spray pattern angle has apredetermined approximate magnitude greater than the second spray angledimension further comprising: a cooling fluid vapor recirculation systemwhich comprises: a cooling fluid vapor outlet at the downstream side ofthe narrow gap cavity, the cooling fluid outlet configured to receivecooling fluid vapor from the narrow gap cavity; and a cooling fluidvapor recirculation inlet configured to receive cooling fluid vaporrouted through the cooling fluid vapor outlet and disposed to directsaid cooling fluid vapor through the narrow gap cavity in theapproximate direction of transverse flow of the cooling fluid; furtherwherein the cooling fluid vapor recirculation system comprises two ormore cooling fluid vapor recirculation inlets each configured to receivecooling fluid vapor routed through the cooling fluid vapor outlet anddisposed to direct said cooling fluid vapor through the narrow gapcavity in the approximate direction of transverse flow of the coolingfluid; and/or further wherein each of the two or more cooling fluidvapor recirculation inlets are disposed to direct said cooling fluidvapor at a pre-determined introduction angle, and further wherein thepre-determined introduction angles are dissimilar to one another.

In another further embodiment of the invention, the narrow gap thin-filmevaporative spray cooling system as recited above is provided, and:further wherein at least one of the plurality of transverse atomizersare oriented at an angle which is approximately three to five degreesdownward from parallel to the circuit card; further wherein across-sectional area of the narrow gap cavity reduces from the atomizersto the cooling fluid outlet; further wherein a cross-sectional area ofthe narrow gap cavity reduces from the atomizers to the cooling fluidoutlet by at least twenty percent; further wherein a cross-sectionalarea of the narrow gap cavity reduces from the atomizers to the coolingfluid outlet by at least forty percent; and/or further wherein at leastone of the plurality of transverse atomizers is oriented at a firstangle and at least one of the plurality of transverse atomizers isoriented at a second angle angle relative to the circuit card.

In another embodiment of the invention, a narrow gap thin-filmevaporative spray cooling system for cooling a plurality of electroniccomponents utilizing a transversely sprayed cooling fluid is provided,comprising: a spray framework with a cooling fluid cavity which includesa cooling fluid inlet; the transverse spray framework defining an atleast partial perimeter around a narrow gap cavity, the narrow gapcavity including, a height, a width greater than the height, and alength, disposed to house a plurality of electronic components to bespray cooled; a plurality of transverse atomizers integral with thetransverse spray framework at a spray side of the transverse sprayframework, the plurality of transverse atomizers being disposed toreceive cooling fluid, and further disposed to spray the cooling fluidtoward the exit side into the narrow gap cavity transverse to theplurality of electronic components; a cooling fluid outlet in fluidcommunication with the cooling fluid cavity, the cooling fluid outletbeing disposed to receive cooling fluid from the narrow gap cavity androute it to a transverse spray framework outlet; and wherein a firstelectronic component is nearer the spray side of the narrow gap cavitythan a second electronic component, and the height of an impingementsurface of the first electronic component is less than the height of animpingement surface of the second electronic component by apre-determined height difference.

In another embodiment of the invention, a narrow gap thin-filmevaporative spray cooling system for cooling a plurality of electroniccomponents utilizing a transversely sprayed cooling fluid is provided,comprising: a spray framework with a cooling fluid cavity which includesa cooling fluid inlet; the transverse spray framework defining an atleast partial perimeter around a narrow gap cavity, the narrow gapcavity including a height, a width greater than the height, and alength, disposed to house a plurality of electronic components to bespray cooled; a plurality of transverse atomizers integral with thetransverse spray framework at a spray side of the transverse sprayframework, the plurality of transverse atomizers being disposed toreceive cooling fluid, and further disposed to spray the cooling fluidtoward the exit side into the narrow gap cavity transverse to theplurality of electronic components; a cooling fluid outlet in fluidcommunication with the cooling fluid cavity, the cooling fluid outletbeing disposed to receive cooling fluid from the narrow gap cavity androute it to a transverse spray framework outlet; wherein impingementsurfaces of the plurality of electronic components are in a staggereddownstream position relative to each other such that the flowcharacteristics of the cooling fluid impacting upstream electroniccomponents does not significantly affect the flow characteristics of thecooling fluid impacting downstream electronic components.

In a further embodiment of the invention, a narrow gap thin-filmevaporative spray cooling system for cooling a plurality of electroniccomponents utilizing a transversely sprayed cooling fluid is provided,comprising: a spray framework with a cooling fluid cavity which includesa cooling fluid inlet; the transverse spray framework defining an atleast partial perimeter around a narrow gap cavity, the narrow gapcavity including a height, a width greater than the height, and alength, disposed to house a plurality of electronic components to bespray cooled; a plurality of transverse atomizers integral with thetransverse spray framework at a spray side of the transverse sprayframework, the plurality of transverse atomizers being disposed toreceive cooling fluid, and further disposed to spray the, cooling fluidtoward the exit side into the narrow gap cavity transverse to theplurality of electronic components; a cooling fluid outlet in fluidcommunication with the cooling fluid cavity, the cooling fluid outletbeing disposed to receive cooling fluid from the narrow gap cavity androute it to a transverse spray framework outlet; wherein the at leastone electronic component has an impingement surface with a spray sideand an exit side, the at least one electronic component being mountedsuch that the spray side of the impingement surface is mounted at alower height than an exit side of the impingement surface, therebycreating a transverse impingement angle. A further embodiment of this isa narrow gap thin-film evaporative spray cooling system wherein thereare a first and second electronic components with impingement surfaces,first electronic component being mounted nearer the spray side than thesecond electronic component, and further wherein the impingement surfaceof the first electronic component is at a lesser impingement angle thanthe impingement surface of the second electronic component.

In another embodiment of the invention, a A method of designing aconfiguration of electronic components of a circuit card in narrow gapthin-film evaporative spray cooling system is provided, comprising thefollowing: providing a circuit card for mounting a plurality ofelectronic components to be spray cooled in a narrow gap thin-filmevaporative spray cooling system, the circuit card having a spray sideand an exit side; and providing the plurality of electronic componentseach with an impingement surface; selectively mounting the plurality ofelectronic components on the circuit card such that the impingementsurfaces of the electronic components toward the spray side are mountedat a height less than the impingement surfaces of the electroniccomponents mounted toward the exit side of the circuit card by apre-determined height difference.

In yet another embodiment of the invention as described in the precedingparagraph, a method of designing a configuration of electroniccomponents of a circuit card in narrow gap thin-film evaporative spraycooling system as stated above, but further comprising selectivelymounting the plurality of electronic components on the circuit card suchthat a spray side of the impingement surfaces of the electroniccomponents are mounted at a lower height than an exit side of theelectronic components.

In another method embodiment of the invention, a method of designing aconfiguration of electronic components of a circuit card in narrow gapthin-film evaporative spray cooling system is providing, comprising thefollowing: providing a circuit card for mounting a plurality ofelectronic components to be spray cooled in a narrow gap thin-filmevaporative spray cooling system, the circuit card having a spray sideand an exit side; and providing the plurality of electronic componentseach with an impingement surface; selectively mounting the plurality ofelectronic components on the circuit card such that impingementsurfaces, of the plurality of electronic components are in a staggereddownstream position relative to one other such that the flowcharacteristics of the cooling fluid impacting upstream electroniccomponents do not significantly affect the flow characteristics of thecooling fluid impacting downstream electronic components. A furtherembodiment of the foregoing is a method of designing a configuration ofelectronic components of a circuit card in narrow gap thin-filmevaporative spray cooling system as recited in claim 13, and furthercomprising: selectively mounting the plurality of electronic componentson the circuit card such that a spray side of the impingement surfacesof the electronic components are mounted at a lower height than an exitside of the electronic components.

A still further embodiment of the invention is a method of designing aconfiguration of electronic components of a circuit card in narrow gapthin-film evaporative spray cooling system, comprising the following:providing a circuit card for mounting at least one electronic componentto be spray cooled in a narrow gap thin-film evaporative spray coolingsystem, the circuit card having a spray side and an exit side; andproviding the at least one electronic component each with an impingementsurface; and selectively mounting the at least one electronic componenton the circuit card such that a spray side of the impingement surfacesof the electronic components are mounted at a lower height than an exitside of the at least one electronic component.

In compliance with the statute, the invention has been described inlanguage more or less specific as to structural and methodical features.It is to be understood, however, that the invention is not limited tothe specific features shown and described, since the means hereindisclosed comprise preferred forms of putting, the invention intoeffect. The invention is, therefore, claimed in any of its forms ormodifications within the proper scope of the appended claimsappropriately interpreted in accordance with the doctrine ofequivalents.

1. A narrow gap thin-film evaporative spray cooling system for coolingat least one electronic component utilizing a transversely sprayedcooling fluid, comprising: a transverse spray framework defining an atleast partial perimeter around a narrow gap cavity, the narrow gapcavity including a height, a width greater than the height, and alength, disposed to house at least one electronic component to be spraycooled; a plurality of transverse atomizers integral with the transversespray framework at a first side of the transverse spray framework, theplurality of transverse atomizers being disposed to receive coolingfluid and to spray the cooling fluid into the narrow gap cavitytransverse to the at least one electronic component; a cooling fluidoutlet in fluid communication with the cooling fluid cavity, disposed toreceive cooling fluid from the narrow gap cavity and route it to atransverse spray framework outlet.; and further wherein across-sectional area of the narrow pan cavity reduces from the atomizersto the cooling fluid outlet.
 2. A narrow gap thin-film evaporative spraycooling system for cooling at least one electronic component utilizing atransversely sprayed cooling fluid, comprising: a transverse sprayframework defining an at least partial perimeter around a narrow gapcavity, the narrow gap cavity including a height, a width greater thanthe height, and a length, disposed to house at least one electroniccomponent to be spray cooled; a plurality of transverse atomizersintegral with the transverse spray framework at a first side of thetransverse spray framework, the plurality of transverse atomizers beingdisposed to receive cooling fluid and to spray the cooling fluid intothe narrow gap cavity transverse to the at least one electroniccomponent; and a cooling fluid outlet in fluid communication with thecooling fluid cavity, disposed to receive cooling fluid from the narrowgap cavity and route it to a transverse spray framework outlet; acooling fluid vapor recirculation system which comprises: a coolingfluid vapor outlet at the downstream side of the narrow gap cavity, thecooling fluid outlet configured to receive cooling fluid vapor from thenarrow gap cavity; and a cooling fluid vapor recirculation inletconfigured to receive cooling fluid vapor routed through the coolingfluid vapor outlet and disposed to direct said cooling fluid vaporthrough the narrow gap cavity in the approximate direction of transverseflow of the cooling fluid.
 3. The narrow gap thin-film evaporative spraycooling system as recited in claim 2, and further wherein the coolingfluid vapor recirculation system comprises two or more cooling fluidvapor recirculation inlets each configured to receive cooling fluidvapor routed through the cooling fluid vapor outlet and disposed todirect said cooling fluid vapor through the narrow gap cavity in theapproximate direction of transverse flow of the cooling fluid.
 4. Thenarrow gap thin-film evaporative spray cooling system as recited inclaim 3, and further wherein each of the two or more cooling fluid vaporrecirculation inlets are disposed to direct said cooling fluid vapor ata pre-determined introduction angle, and further wherein thepre-determined introduction angles are dissimilar to one another.
 5. Anarrow gap thin-film evaporative spray cooling system for cooling atleast one electronic component utilizing a transversely sprayed coolingfluid, comprising: a transverse spray framework defining an at leastpartial perimeter around a narrow gap cavity, the narrow gap cavityincluding a height, a width greater than the height, and a length,disposed to house at least one electronic component to be spray cooled;a plurality of transverse atomizers integral with the transverse sprayframework at a first side of the transverse spray framework, theplurality of transverse atomizers being disposed to receive coolingfluid and to spray the cooling fluid into the narrow gap cavitytransverse to the at least one electronic component; and a cooling fluidoutlet in fluid communication with the cooling fluid cavity, disposed toreceive cooling fluid from the narrow gap cavity and route it to atransverse spray framework outlet; and further wherein a cross-sectionalarea of the narrow gap cavity reduces from the atomizers to the coolingfluid outlet by at least twenty percent.
 6. A narrow gap thin-filmevaporative spray cooling system for cooling at least one electroniccomponent utilizing a transversely sprayed cooling fluid, comprising: atransverse spray framework defining an at least partial perimeter arounda narrow gap cavity, the narrow gap cavity including a height, a widthgreater than the height, and a length, disposed to house at least oneelectronic component to be spray cooled; a plurality of transverseatomizers integral with the transverse spray framework at a first sideof the transverse spray framework, the plurality of transverse atomizersbeing disposed to receive cooling fluid and to spray the cooling fluidinto the narrow gap cavity transverse to the at least one electroniccomponent; and a cooling fluid outlet in fluid communication with thecooling fluid cavity, disposed to receive cooling fluid from the narrowgap cavity and route it to a transverse spray framework outlet; andfurther wherein a cross-sectional area of the narrow gap cavity reducesfrom the atomizers to the cooling fluid outlet by at least fortypercent.
 7. A narrow gap thin-film evaporative spray cooling system forcooling a plurality of electronic components utilizing a transverselysprayed cooling fluid, comprising: a spray framework with a coolingfluid cavity which includes a cooling fluid inlet; the transverse sprayframework defining an at least partial perimeter around a narrow gapcavity, the narrow gap cavity including a height, a width greater thanthe height, and a length, disposed to house a plurality of electroniccomponents to be spray cooled; a plurality of transverse atomizersintegral with the transverse spray framework at a spray side of thetransverse spray framework, the plurality of transverse atomizers beingdisposed to receive cooling fluid, and further disposed to spray thecooling fluid toward the exit side into the narrow gap cavity transverseto the plurality of electronic components; a cooling fluid outlet influid communication with the cooling fluid cavity, the cooling fluidoutlet being disposed to receive cooling fluid from the narrow gapcavity and route it to a transverse spray framework outlet; and whereina first electronic component is nearer the spray side of the narrow gapcavity than a second electronic component, and the height of animpingement surface of the first electronic component is less than theheight of an impingement surface of the second electronic component by apre-determined height difference.
 8. A narrow gap thin-film evaporativespray cooling system for cooling a plurality of electronic componentsutilizing a transversely sprayed cooling fluid, comprising: a sprayframework with a cooling fluid cavity which includes a cooling fluidinlet; the transverse spray framework defining an at least partialperimeter around a narrow gap cavity, the narrow gap cavity including aheight, a width greater than the height, and a length, disposed to housea plurality of electronic components to be spray cooled; a plurality oftransverse atomizers integral with the transverse spray framework at aspray side of the transverse spray framework, the plurality oftransverse atomizers being disposed to receive cooling fluid, andfurther disposed to spray the cooling fluid toward the exit side intothe narrow gap cavity transverse to the plurality of electroniccomponents; a cooling fluid outlet in fluid communication with thecooling fluid cavity, the cooling fluid outlet being disposed to receivecooling fluid from the narrow gap cavity and route it to a transversespray framework outlet; wherein impingement surfaces of the plurality ofelectronic components are in a staggered downstream position relative toeach other such that the flow characteristics of the cooling fluidimpacting upstream electronic components does not significantly affectthe flow characteristics of the cooling fluid impacting downstreamelectronic components.
 9. A narrow gap thin-film evaporative spraycooling system for cooling a plurality of electronic componentsutilizing a transversely sprayed cooling fluid, comprising: a sprayframework with a cooling fluid cavity which includes a cooling fluidinlet; the transverse spray framework defining an at least partialperimeter around a narrow gap cavity, the narrow gap cavity including aheight, a width greater than the height, and a length, disposed to housea plurality of electronic components to be spray cooled; a plurality oftransverse atomizers integral with the transverse spray framework at aspray side of the transverse spray framework, the plurality oftransverse atomizers being disposed to receive cooling fluid , andfurther disposed to spray the cooling fluid toward the exit side intothe narrow gap cavity transverse to the plurality of electroniccomponents; a cooling fluid outlet in fluid communication with thecooling fluid cavity, the cooling fluid outlet being disposed to receivecooling fluid from the narrow gap cavity and route it to a transversespray framework outlet; wherein the at least one electronic componenthas an impingement surface with a spray side and an exit side, the atleast one electronic component being mounted such that the spray side ofthe impingement surface is mounted at a lower height than an exit sideof the impingement surface, thereby creating a transverse impingementangle.
 10. A narrow gap thin-film evaporative spray cooling system asprovided in claim 9, and wherein there are a first and second electroniccomponents with impingement surfaces, first electronic component beingmounted nearer the spray side than the second electronic component, andfurther wherein the impingement surface of the first electroniccomponent is at a lesser impingement angle than the impingement surfaceof the second electronic component.
 11. A method of designing aconfiguration of electronic components of a circuit card in narrow gapthin-film evaporative spray cooling system, comprising the following:providing a circuit card for mounting a plurality of electroniccomponents to be spray cooled in a narrow gap thin-film evaporativespray cooling system, the circuit card having a spray side and an exitside; and providing the plurality of electronic components each with animpingement surface; selectively mounting the plurality of electroniccomponents on the circuit card such that the impingement surfaces of theelectronic components toward the spray side are mounted at a height lessthan the impingement surfaces of the electronic components mountedtoward the exit side of the circuit card by a pre-determined heightdifference.
 12. A method of designing a configuration of electroniccomponents of a circuit card in narrow gap thin-film evaporative spraycooling system as recited in claim 11, and further comprising:selectively mounting the plurality of electronic components on thecircuit card such that a spray side of the impingement surfaces of theelectronic components are mounted at a lower height than an exit side ofthe electronic components.
 13. A method of designing a configuration ofelectronic components of a circuit card in narrow gap thin-filmevaporative spray cooling system, comprising the following: providing acircuit card for mounting a plurality of electronic components to bespray cooled in a narrow gap thin-film evaporative spray cooling system,the circuit card having a spray side and an exit side; and providing theplurality of electronic components each with an impingement surface;selectively mounting the plurality of electronic components on thecircuit card such that impingement surfaces of the plurality ofelectronic components are in a staggered downstream position relative toone other such that the flow characteristics of the cooling fluidimpacting upstream electronic components do not significantly affect theflow characteristics of the cooling fluid impacting downstreamelectronic components.
 14. A method of designing a configuration ofelectronic components of a circuit card in narrow gap thin-filmevaporative spray cooling system as recited in claim 13, and furthercomprising: selectively mounting the plurality of electronic componentson the circuit card such that a spray side of the impingement surfacesof the electronic components are mounted at a lower height than an exitside of the electronic components.
 15. A method of designing aconfiguration of electronic components of a circuit card in narrow gapthin-film evaporative spray cooling system, comprising the following:providing a circuit card for mounting at least one electronic componentto be spray cooled in a narrow gap thin-film evaporative spray coolingsystem, the circuit card having a spray side and an exit side; andproviding the at least one electronic component each with an impingementsurface; selectively mounting the at least one electronic component onthe circuit card such that a spray side of the impingement surfaces ofthe electronic components are mounted at a lower height than an exitside of the at least one electronic component.
 16. A narrow gapthin-film evaporative spray cooling system for cooling at least oneelectronic component utilizing a transversely sprayed cooling fluid,comprising: a transverse spray framework defining an at least partialperimeter around a narrow gap cavity, the narrow gap cavity including aheight, a width greater than the height, and a length, disposed to housea first electronic component and a second electronic component, whichare to be spray cooled; a plurality of transverse atomizers integralwith the transverse spray framework at a first side of the transversespray framework, the plurality of transverse atomizers being disposed toreceive cooling fluid and to spray the cooling fluid into the narrow gapcavity transverse to the at least one electronic component; a gap fillerpositioned between and approximately at top surface of the firstelectronic component and the second electronic component, the gap fillerdisposed to provide a coolant flow surface between electronic componentsfor cooling fluid ; and a cooling fluid outlet in fluid communicationwith the cooling fluid cavity, disposed to receive cooling fluid fromthe narrow gap cavity and route it to a transverse spray frameworkoutlet.